Composite Laser Ablation for Surface Preparation (CLASP) Manufacturing Scale-up

TECH FOCUS AREAS: General Warfighting Requirements (GWR) TECHNOLOGY AREAS: Materials; Air Platform OBJECTIVE: The Composite Laser Ablation for Surface Preparation (CLASP) manufacturing scale-up objective is to take the one-off working handheld prototype and transform it into a set of production ready tools. Since these tools will be utilized on a manufacturing floor, they must be robust, easy to use, meet all governing safety regulations, and perform in a highly efficient and effective manner. They must be adapted for better handheld uses and for higher through put operations such as gantry type of set up where the CLASP tool is stationary and the part needing surface preparation moves under it. In addition, the scale up effort will improve prototype surface preparation time by 25%. DESCRIPTION: CLASP manufacturing scale-up will refine the prototype handheld unit into a reliable production factory floor set of tools while enhancing its capability and improving its operating efficiency. Proper composite part surface preparation is critical in achieving a strong bond for structural capacity. The current surface preparation method is hand sanding which is extremely time consuming. In addition, the surface preparation is highly variable and thus, introduces structural integrity uncertainties into the bond between the composite parts. CLASP will improve the through put and surface quality for composite part bonding. The scale-up will redesign the handheld prototype into robust high-quality parts for assembly line type manufacture of the tool. The design will be highly ergonomic for handheld operations but also tailored for robotic or gantry type utilization for high output surface preparation. Disposal of ablated surface debris will be 100% contained as to not contaminate the just prepared clean surface. All fiber optic laser cables, debris removal hoses, power lines, user interface display cables and surface offset contact leads will be routed for ease of mobility and safety on the production floor. PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the Phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of advanced manufacturing and/or sustainment relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. Air Force sustainment stakeholder engagement is paramount to successful validation of the technical approach. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: Palmieri, F.L., Ledesma, R. et al., Optimized Surface Treatment of Aerospace Composites using a Picosecond Laser, Composites Part B: Engineering, 2019. Belcher, M.A, Blohowiak, K.Y., Wohl, C.J., Connell, J.W. and Palmieri, F.L., Laser Ablation Surface Preparation for Adhesive Bonding of Carbon Fiber Reinforced Epoxy, Int. Journal of Adhesion and Adhesives, 2016. Cargill, R.L. and Wool, M.R., Surface Preparation of Organic Matrix Composites (OMCs) for Structural Adhesive Bonding, AFRL-RX-WP-TR-2013-0178, March 2013. AFD 2053 Invention Disclosure Prepregs and Cured Composites Having Improved Surfaces and Processes of Making and Methods of Using Same (Adam Hicks, copied here, has patent invention disclosure details) KEYWORDS: Manufacturing scale-up; handheld unit; production factory floor set of tools; proper composite part surface preparation; tailored for robotic or gantry type utilization;